System and Method for Transfixing an Aqueous Ink in an Image Transfer System

ABSTRACT

An image transfer medium for transferring an ink image onto a substrate is provided on its surface with a layer of particles that include an aggregation treatment agent capable of crashing out colorants, latex and/or resin in the liquid ink. The particles can include a surfactant or separate particles consisting essentially of a surfactant can be mixed with particles consisting essentially of the aggregation treatment agent.

REFERENCE TO RELATED APPLICATION AND PRIORITY CLAIM

This application is a continuation of and claims priority to co-pendingapplication Ser. No. 13/943,473, entitled “System and Method forTransfixing an Aqueous Ink in an Image Transfer System”, filed on Jul.16, 2013, the entire disclosure of which is incorporated herein byreference.

TECHNICAL FIELD

The present disclosure relates to printing, copying and image transfermachines, marking engines and the like. In particular the disclosurerelates to liquid or aqueous ink transfer systems and methods for suchmachines.

BACKGROUND

In certain indirect printing systems, an ink image is applied onto animage transfer medium, and this image is then transferred to a secondsubstrate, typically without the application of heat. The image can betransferred using minimal or low pressure applied to the back surface ofthe transfer medium, after which the medium is removed. The first stepin the transfix process requires printing the liquid ink onto the imagetransfer medium, which typically occurs by directing ink droplets ontothe surface of the medium. In this step it is necessary for the ink tosufficiently wet the surface of the transfer medium so that the inkdroplet does not drawback in an uncontrolled or random manner. Excessiveink drawback significantly reduces transfixed image quality since thedroplet is either randomly spread onto the substrate or fails totransfer properly.

Another aspect of the aqueous transfix process is that the ink becomespartially dried before being transfixed, so the partially dried ink muststill be able to transfer easily and completely from image transfermedium to substrate, leaving very little residue behind. Thus, thesurface of the image transfer medium must juggle two generally mutuallyexclusive characteristics—surfaces which are sufficiently wettable tendto resist transfer of the ink to the substrate and surfaces that havegood transfer characteristics tend to resist wetting.

There is a need for an aqueous image transfer system and method thatbalances these two important aspects of the image transfer process for aliquid or aqueous ink system. The system and method must also be capableof initiating and sustaining crashing, aggregating or precipitating ofcolorants in the liquid or aqueous ink after it is applied to the imagetransfer medium.

SUMMARY OF THE DISCLOSURE

In one aspect of the present disclosure, a method for transfixing aliquid or aqueous ink image contemplates providing an image transfermedium; applying a layer of particles to the image transfer medium, theparticles including an aggregation treatment agent capable of crashingout, aggregating or precipitating colorants, latex and/or resin inliquid ink; applying liquid ink drops to the image transfer medium;initiating crashing aggregating or precipitating of the colorant, latexand/or resin in the ink drops upon contact with the particles; and upona sufficient amount of crashing aggregating or precipitating, contactinga second substrate to the image transfer medium to transfer the ink fromthe transfer medium to the second substrate.

In another aspect of the present disclosure, an image transfer medium isprovided with a layer of particles on the surface of the medium. Theparticles includes an aggregation treatment agent capable of crashingout, aggregating or precipitating colorants, latex and/or resin inliquid ink. The aggregation treatment agent may include a metal saltsuch as iron sulfate or copper sulfate.

DESCRIPTION OF THE FIGURES

FIG. 1 is diagram of a liquid ink drop applied to a surface of an imagetransfer medium with a layer of particles capable of crashingaggregating or precipitating colorant in the ink.

FIG. 2 is a diagram of the ink drop as the colorant is crashedaggregated or precipitated out of the ink.

FIG. 3 is a diagram of the ink drop after the colorant as beensubstantially crashed aggregated or precipitated out of the ink drop bythe particles.

FIG. 4(a) is a photograph of ink drops applied in a linear pattern tothe surface of a conventional image transfer medium showing the gapsbetween the drops.

FIG. 4(b) is a photograph of ink drops applied in a linear pattern tothe surface of an image transfer medium in which the surface includes alayer of iron sulfate particles.

FIG. 4(c) is a photograph of ink drops applied in a linear pattern tothe surface of an image transfer medium in which the surface includes alayer of copper sulfate particles.

FIG. 5(a) is a photograph of ink drops applied in a linear pattern tothe surface of a conventional image transfer medium in which the surfaceis roughened, the photograph showing the gaps between the drops.

FIG. 5(b) is a photograph of ink drops applied in a linear pattern tothe roughened surface of an image transfer medium in which the surfaceincludes a layer of iron sulfate particles.

FIG. 5(c) is a photograph of ink drops applied in a linear pattern tothe roughened surface of an image transfer medium in which the surfaceincludes a layer of copper sulfate particles.

DETAILED DESCRIPTION

The present disclosure contemplates a system and method for transfixinga liquid or aqueous ink to a substrate. For purposes of the presentdisclosure, the ink is an aqueous solution that includes colorants andthat is adapted for deposition as droplets onto a surface throughconventional means, such as by a plurality of ink jet devicecontrollable to apply the ink droplets in the image pattern. The inkdroplets are deposited onto the surface of an image transfer medium orblanket. The blanket may be formed of various materials that aresuitable to retain small particles deposited thereon, as explained inmore detail herein. For instance, the blanket may be a silicone plate ordrum.

In a first step of the method disclosed herein, a large number of smallparticles are deposited uniformly onto the blanket surface. Theparticles include agents or compounds suitable to crash out aggregate orprecipitate the colorants in the liquid ink. For the purposes of thepresent disclosure, the term “aggregation treatment agent” is used torefer to these agents or compounds that are capable of aggregatingcolorants, latex and/or resin out of an ink drop by any suitablemechanism, including but not limited to precipitation. The particles maybe very small, on the order of 1.0-10.0 μm in effective diameter and aredistributed uniformly and with uniform density onto the blanket surface.In one aspect, the particle coverage or density is low enough (e.g.,significantly less than 50%) so that the particles do not form acontiguous large patch of particles. On the other hand, the particlecoverage is high enough (e.g., greater than 5%) so that the averagedistance between the particles is less than a few microns so that manyparticles are within the range of impact for a drop of ink. Thus, theparticle distribution may be in a coverage range of between 5 and about40%.

The particles may be deposited using a number of techniques, includingknown electrostatic printing methods such as electrostatically biasedroll/brush/cloud development with particles charged throughtriboelectric charging or ion charging. Another suitable technique iselectrostatic precipitation in which an air flow of airborne particlesis created across the blanket surface. The particles capture charge froman ion flow perpendicular to the surface generated, for example, by acorotron, and then precipitate onto the blanket surface. Adhesiondusting can be implemented in another approach in which the particlesare coarsely dusted onto the blanket surface and then excess particlesare removed by light brushing or air flow. Since theparticle-to-particle cohesion is weaker than the particle-to-surfacecohesion a dense and uniform layer of particles can be produced. Thislatter method is particularly useful for the particle coverage range setforth above since the method is robust against the particle densitybeing either too high or too low.

In the next step of the method disclosed herein, ink droplets areapplied to the layer of particles, as illustrated schematically inFIG. 1. When the droplet of ink strikes the surface, the colorant orpigment begins to precipitate out of the ink due to the aggregationtreatment agent(s) within the particles, as represented in FIG. 2. Asthe precipitation or crashing continues, a coating of pigment andcarrier (such as resin or latex) is formed on the blanket surface. Theparticles further act to pin the droplet to the blanket surface, whichhas a two-fold impact. First, pinning the droplet to the surface allowsthe aggregation treatment agent(s) in the particles to diffuse throughthe droplet and cause further crashing of the ink, as illustrated inFIG. 3.

Second, pinning the droplet to the surface prevents it from drawingback, which ensures that the liquid ink is sufficiently dispersed on thetransfer medium or blanket so that the quality of the transferred imageis maintained. An example of this effect is demonstrated in tests inwhich ink droplets of about 14 picoliters are deposited on differentsurfaces, with the results shown in the comparative diagrams of FIG. 4.The control strip of FIG. 4(a) is a standard aqueous ink deposition ontoa silicon plate. The ink droplets draw back so that gaps (i.e., thespace between droplets) occupy about 51% of each strip. In contrast, thestrips of FIGS. 4(b) and (c) were produced by the same aqueous inkapplied to surfaces treated as described above. The difference betweenthe two strips is in the aggregation treatment agent of the particlesapplied to the plate surface. In one case, FIG. 4(b), the gaps occupiedonly 39% of each strip, while in the other case, FIG. 4(c), the gapswere reduced to only 16% of the strip length.

A further benefit may be obtained by depositing the particles on aroughened surface. In tests illustrated in the comparative diagrams ofFIG. 5, a silicon plate is roughened such as by shot peening. As seen bycomparing FIG. 5(a) with FIG. 4(a), the roughened surface yieldssignificantly smaller gaps, 21%, than the smooth surface control testvalue of 51%. Similar improvements are seen with the prepared surfacesof FIGS. 5(b), (c), with both surfaces producing a small 12% gap.

The particle or powder layer described above may be applied to thesurface of an image transfer medium. The ink drops may be applied usingan ink jet or other known mechanism for applying ink drops to a surface.When the ink drops strike the surface of the transfer medium, theaggregation treatment agents immediately begin dissolving in the ink andcrashing out the pigment. Once the pigment has sufficiently crashed outof the ink and the ink drop has been adequately dried, the imagetransfer medium can be brought into contact with a second substrate totransfer the color image according to known techniques. Drying of theink drops can be hastened by applying heat, such as by flowing heatedair across the surface of the image transfer medium. The system andmethod described herein improves the image transfer characteristics foran aqueous color ink so that the resulting transferred image is sharperand more complete than with prior systems and methods.

As indicated above, the particles or powder contain agents or compoundsthat cause pigment and/or resin and/or latex to crash out of the inkdrop to produce a color drop on the receiving substrate. In the testsdocumented in FIGS. 4-5 the particles were iron sulfate and coppersulfate, with the copper sulfate showing the narrower gaps in FIG. 4(c).It is contemplated that the particle agents may include other metalsalts with metal ions selected from Ca, Cu, Ni, Mg, Zn, Fe and Al. It isfurther believed that certain anions may also be suitable to crash outpigments, resin and/or latex from an ink drop. These anions may includeCl, NO₃, SO₄, I, Br, ClO₃ and RCOO—, where R is an alkyl group.

The aggregation treatment agents may be combined with other additives toform the particles or powders described above. For instance, asurfactant may be incorporated into the particles or separate surfactantparticles may be mixed with particles of the aggregation treatmentagent. The surfactant may dissolve in the ink drop to reduce the surfacetension of the drop at contact. Reducing surface tension can improvesurface wetting, thereby reducing the gap between successive ink dropson the image transfer medium.

While the invention has been illustrated and described in detail in thedrawings and foregoing description, the same should be considered asillustrative and not restrictive in character. It is understood thatonly the preferred embodiments have been presented and that all changes,modifications and further applications that come within the spirit ofthe invention are desired to be protected.

What is claimed is:
 1. An image transfer medium for transferring an inkimage onto a substrate, comprising: a surface adapted to receive liquidink and to engage the substrate to transfer an ink image thereto; and alayer of particles affixed on said surface to receive the liquid ink,each of said particles including a surfactant and an aggregationtreatment agent capable of crashing out colorants, latex and/or resin inthe liquid ink.
 2. The image transfer medium of claim 1, wherein theaggregation treatment agent includes a metal salt.
 3. The image transfermedium of claim 2, wherein the metal salt includes metal ions selectedfrom the group Ca, Cu, Ni, Mg, Zn, Fe and Al.
 4. The method fortransferring an ink image of claim 3, wherein the particles include oneor more of copper sulfate and iron sulfate.
 5. The image transfer mediumof claim 1, wherein the aggregation treatment agent includes an anioncapable of crashing the colorant, latex and/or resin.
 6. The imagetransfer medium of claim 5, wherein the aggregation treatment agentincludes anions containing one or more of NO₃, SO₄, I, Br, ClO₃ andRCOO—, where R is an alkyl group.
 7. The image transfer medium of claim1, wherein the particles are distributed substantially uniformly with adensity in the range of 5%-40% on the surface.
 8. The image transfermedium of claim 1, wherein each of the particles has a diameter of1.0-10.0 μm.
 9. The image transfer medium of claim 1, wherein theparticles are affixed on the surface by one or more of the techniquesincluding triboelectric or ion charging, electrostatic precipitation andadhesion dusting.
 10. The image transfer medium of claim 1, wherein thesurface is roughened with the layer of particles disposed on theroughened surface.
 11. An image transfer medium for transferring an inkimage onto a substrate, comprising: a surface adapted to receive liquidink and to engage the substrate to transfer an ink image thereto; and alayer of particles affixed on said surface to receive the liquid ink,the layer of particles including particles consisting essentially of asurfactant mixed with particles consisting essentially of an aggregationtreatment agent capable of crashing out colorants, latex and/or resin inthe liquid ink.
 12. The image transfer medium of claim 11, wherein theaggregation treatment agent includes a metal salt having metal ionsselected from the group Ca, Cu, Ni, Mg, Zn, Fe and Al.
 13. The imagetransfer medium of claim 11, wherein the aggregation treatment agentincludes anions containing one or more of NO₃, SO₄, I, Br, ClO₃ andRCOO—, where R is an alkyl group.
 14. The image transfer medium of claim11, wherein the particles including the aggregation treatment agent aredistributed substantially uniformly with a density in the range of5%-40% on the surface.
 15. The image transfer medium of claim 11,wherein the particles including the aggregation treatment agent have adiameter of 1.0-10.0 μm.
 16. The image transfer medium of claim 11,wherein the surface is roughened with the layer of particles disposed onthe roughened surface.
 17. A composition to be affixed on the surface ofan image transfer medium for transferring an ink image onto a substrate,the surface adapted to receive liquid ink and to engage the substrate totransfer an ink image thereto, the composition comprising: a pluralityof particles adapted to be affixed on said surface by one oftriboelectric or ion charging, electrostatic precipitation and adhesiondusting, wherein either (a) each of said plurality of particles includesa surfactant and an aggregation treatment agent capable of crashing outcolorants, latex and/or resin in the liquid ink, or (b) said pluralityof particles includes particles consisting essentially of a surfactantmixed with particles consisting essentially of an aggregation treatmentagent capable of crashing out colorants, latex and/or resin in theliquid ink.
 18. The image transfer medium of claim 17, wherein theaggregation treatment agent includes a metal salt having metal ionsselected from the group Ca, Cu, Ni, Mg, Zn, Fe and Al.
 19. The imagetransfer medium of claim 17, wherein the aggregation treatment agentincludes anions containing one or more of NO₃, SO₄, I, Br, ClO₃ andRCOO—, where R is an alkyl group.
 20. The image transfer medium of claim11, wherein each of the plurality of particles has a diameter of1.0-10.0 μm.